Hurco VM Series User guide

February 2012 704-0212-209 Revision B
MAINTENANCE AND SAFETY
MANUAL
for VM Series
Machining Centers

ii - Maintenance and Safety Manual 704-0212-209 VM Series Maintenance and Safety Manual
The information in this document is subject to change without notice and does not
represent a commitment on the part of Hurco Companies, Inc. (Hurco). The software
described in this document is furnished under the License Agreement to customers. It is
against the law to copy the software on any medium except as specifically allowed in the
license agreement. The purchaser may make copies of the software for backup purposes.
No part of this document may be reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopying, for any purpose without the express
written permission of the Hurco machine tool owner.
Hurco Manufacturing Company reserves the right to incorporate any modification or
improvements in machines and machine specifications which it considers necessary, and
does not assume any obligation to make any said changes in machines or equipment
previously sold.
Hurco products and services are subject to Hurco’s then current prices, terms, and
conditions, which are subject to change without notice.
© 2012 Hurco Companies, Inc. All rights reserved.
Patents: U.S. Patents B14,477,754; 5,453,933; Canadian Patent 1,102,434;
Japanese Patents 1,649,006 and 1,375,124; other Patents pending.
Hurco, Max, Ultimax, and WinMax are Registered Trademarks of Hurco Companies, Inc.
AutoCAD, Autodesk, and DXF are registered trademarks of Autodesk, Inc.
MS-DOS, Microsoft, and Windows are registered trademarks of Microsoft Corporation.
Many of the designations used by manufacturers and sellers to distinguish their products
are claimed as trademarks. Hurco has listed here all trademarks of which it is aware. For
more information about Hurco products and services, contact:
Hurco Companies, Inc.
One Technology Way
P.O. Box 68180
Indianapolis, IN 46268-0180
Tel [phone] (products)
[phone] (service)
Fax [phone] (service)
For Hurco subsidiary contact information, go to Hurco’s Web site:
www.hurco.com

VM Series Maintenance and Safety Manual 704-0212-209 VM Maintenance Checklist — iii
VM MAINTENANCE CHECKLIST
Daily (Every 8 - 10 Hours)
Perform operational checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
Check the USB port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4
Check and maintain all lubricant levels. . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
Clean the tool lock pins and tool gripper fingers. . . . . . . . . . . . . . . . . . . . 3- 10
Check the condition of tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 11
Lubricate the non-motorized spindle taper. . . . . . . . . . . . . . . . . . . . . . . . 3- 13
Maintain the spindle chiller system (if equipped). . . . . . . . . . . . . . . . . . . . 3- 14
Check the spindle chiller (if equipped) working environment, ventilation, and
ambient temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 16
Check the FRL unit air pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 22
Check the auto moisture drain on FRL. . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 23
Check the coolant level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 25
Clean the chip conveyor tank (if equipped) chip screens. . . . . . . . . . . . . . 3- 27
Inspect the enclosure windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 29
Check the trunnion table (if equipped) clamping system’s incoming
pneumatic lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 30
Clean the trunnion table (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 31
Check the rotary-axis oil level (if equipped). . . . . . . . . . . . . . . . . . . . . . . 3- 31
Check the tilt-axis oil (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 32
Warm up the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 33
Weekly (Every 40 - 50 Hours)
Clean the filter inside the heat exchanger. . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4
Check each tool holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 12
Inspect the chiller solution level (if equipped). . . . . . . . . . . . . . . . . . . . . . 3- 13
Inspect the spindle chiller tank air filter and water filter (if equipped). . . . . 3- 14
Clean the coolant filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 25
Check the CTS coolant filter (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . 3- 26
Check the oil level for the clamping system (if equipped). . . . . . . . . . . . . . 3- 30
Monthly (Every 150-200 Hours)
Inspect conduit, connectors, cabling, and external wiring. . . . . . . . . . . . . . 3 - 4
Add a rust preventative to the Autolube system. . . . . . . . . . . . . . . . . . . . 3 - 7
Maintain the autolube fluid level and check the filler filter screen. . . . . . . . 3 - 7
Manually activate the Autolube system. . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
Inspect limit switches and dog fasteners for damage. . . . . . . . . . . . . . . . . 3- 28
Perform a spindle run-in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 36
Do not attempt to access the machine enclosure while machine
power is on. Observe proper lock-out/tag-out procedures before
performing any maintenance inside the machine enclosure.

iv - VM Maintenance Checklist 704-0212-209 VM Series Maintenance and Safety Manual
Every 3 Months (Every 500 Hours or as stated)
Check the ATC oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9
Drain moisture from the lines of the FRL. . . . . . . . . . . . . . . . . . . . . . . . . . 3- 23
Replace coolant and coolant filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 25
Replace the CTS coolant filter (if equipped). . . . . . . . . . . . . . . . . . . . . . . . 3- 26
Clean the chip conveyor tank (if equipped). . . . . . . . . . . . . . . . . . . . . . . . 3- 27
Measure the ground impedance (resistance to true earth). . . . . . . . . . . . . . 3- 29
Every 6 Months (Every 1000 Hours or as stated)
Grease the ATC magazine chain assembly . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9
Verify the machine is sitting level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 29
Annually (Every 2000 Hours or as stated)
Clean the autolube reservoir tank and suction filter. . . . . . . . . . . . . . . . . . . 3 - 8
Replace the ATC oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9
Flush, clean, and refill the spindle chiller tank (if equipped).. . . . . . . . . . . . . 3- 15
Replace the rotary-axis oil (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 31
Replace the tilt-axis oil (if equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 32

VM Series Maintenance and Safety Manual 704-0212-209 Table of Contents — v
TABLE OF CONTENTS
Maintenance and Safety Manual for Your VM Machining Center
VM Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Documentation Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
Machine Model Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Spindle and Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
Axes Motion System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12
Machine Electrical Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 15
Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 28
Operator Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 28
Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 32
Pneumatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 33
VM10G Dust Collector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 33
Trunnion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 34
Automatic Tool Changer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 35
Operation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
Machine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2
Initial Test and Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
Machinery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6
Proper Operation and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 10
Noise Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13
Machine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
Daily Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
USB Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4
Exterior Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
Pneumatic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 22
Flood Coolant and Washdown System . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 24
Chip Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 27
Dust Collector—VM10G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 28
Limit Switches and Dogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 28
Machine Electrical Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 29
Machine Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 29
Enclosure Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 29
Trunnion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 30
Machine Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 33
Spindle Run-in or Cycle Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 36
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 39
Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 46
Record of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

vi - List of Figures 704-0212-209 VM Series Maintenance and Safety Manual
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IX - 1
LIST OF FIGURES
Figure 1–1. Full Chip and Coolant Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Figure 1–2. Example of Belt-Driven Spindle and Drive . . . . . . . . . . . . . . . . . . . 1 - 7
Figure 1–3. Mini-ITX Card Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 16
Figure 1–4. Slice I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 20
Figure 1–5. Communication Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 21
Figure 1–6. Communication Port Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 25
Figure 1–7. Male 9-Pin D-Type Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 26
Figure 1–8. Dual-Screen Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 28
Figure 1–9. Max Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 29
Figure 3–1. Autolube Pump and Tank Assembly . . . . . . . . . . . . . . . . . . . . . . 3 - 6
Figure 3–2. HWK Spindle Chiller Control Panel . . . . . . . . . . . . . . . . . . . . . . . . 3- 18
Figure 3–3. HWT Spindle Chiller Control Panel . . . . . . . . . . . . . . . . . . . . . . . . 3- 20
Figure 3–4. Filter, Regulator, and Lubricator Unit . . . . . . . . . . . . . . . . . . . . . . 3- 22
LIST OF TABLES
Table 1–12. Axis Maximum Travel, English . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 12
Table 1–13. Rapid Traverse Rates, Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 13
Table 1–14. Rapid Traverse Rates, English . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 13
Table 1–15. Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 25
Table 1–16. RS-232C Signals Available at Serial Port . . . . . . . . . . . . . . . . . . . . 1- 26
Table 1–17. Trunnion Table Maximum Allowable Workpiece Weight, Metric . . . . 1- 34
Table 1–18. Trunnion Table Maximum Allowable Workpiece Weight, English . . . . 1- 34
Table 1–19. ATC Tool Specifications, Metric . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 35
Table 1–20. ATC Tool Specifications, English . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 35
Table 2–1. Maximum Noise Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 13
Table 3–1. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
Table 3–2. Differential Temperature Cooling process . . . . . . . . . . . . . . . . . . . 3- 17
Table 3–3. 6000 Max RPM Spindle Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . 3- 33
Table 3–4. 8000 Max RPM Spindle Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . 3- 33
Table 3–5. 10000 Max RPM Spindle Warm-up . . . . . . . . . . . . . . . . . . . . . . . . 3- 33
Table 3–6. 12000 Max RPM Spindle Warm-up . . . . . . . . . . . . . . . . . . . . . . . . 3- 34
Table 3–7. 15000 Max RPM Spindle Warm-up . . . . . . . . . . . . . . . . . . . . . . . . 3- 34
Table 3–8. 18000 Max RPM Spindle Warm-up . . . . . . . . . . . . . . . . . . . . . . . . 3- 34
Table 3–9. 20000 Max RPM Spindle Warm-up . . . . . . . . . . . . . . . . . . . . . . . . 3- 35
Table 3–10. 30000 Max RPM Spindle Warm-up . . . . . . . . . . . . . . . . . . . . . . . . 3- 35
Table 3–11. 600 Max RPM Spindle Run-in or Cycle . . . . . . . . . . . . . . . . . . . . . 3- 36
Table 3–12. 8000 Max RPM Spindle Run-in or Cycle . . . . . . . . . . . . . . . . . . . . . 3- 36
Table 3–13. 10000 Max RPM Spindle Run-in or Cycle . . . . . . . . . . . . . . . . . . . . 3- 37
Table 3–14. 12000 Max RPM Spindle Run-in or Cycle . . . . . . . . . . . . . . . . . . . . 3- 37
Table 3–15. 15000 Max RPM Spindle Run-in or Cycle . . . . . . . . . . . . . . . . . . . . 3- 37
Table 3–16. 18000 Max RPM Spindle Run-in or Cycle . . . . . . . . . . . . . . . . . . . . 3- 38
Table 3–17. 20000 Max RPM Spindle Run-in or Cycle . . . . . . . . . . . . . . . . . . . . 3- 38

VM Series Maintenance and Safety Manual 704-0212-209 List of Tables - vii
Table 3–18. 30000 Max RPM Spindle Run-in or Cycle . . . . . . . . . . . . . . . . . . . . 3- 38
Table 3–19. Troubleshooting: Missing or Faulty Connections . . . . . . . . . . . . . . . 3- 42
Table 3–20. Troubleshooting: Power Fluctuation . . . . . . . . . . . . . . . . . . . . . . . 3- 42
Table 3–21. Troubleshooting: Coolant System . . . . . . . . . . . . . . . . . . . . . . . . 3- 43
Table 3–22. Troubleshooting: Spindle Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 43
Table 3–23. Troubleshooting: Power Off Motion Error . . . . . . . . . . . . . . . . . . . 3- 44
Table 3–24. Troubleshooting: Machine Chatter . . . . . . . . . . . . . . . . . . . . . . . . 3- 44
Table 3–25. Troubleshooting: Errors in Dimensions . . . . . . . . . . . . . . . . . . . . . 3- 45
Table 3–26. Troubleshooting: Environmental Factors . . . . . . . . . . . . . . . . . . . 3- 45

viii - List of Tables 704-0212-209 VM Series Maintenance and Safety Manual

VM Series Maintenance and Safety Manual 704-0212-209 Documentation Conventions — ix
DOCUMENTATION CONVENTIONS
This documentation uses several conventions to explain the safety features and
emphasize key concepts. These conventions are described in this section.
Additional information is available on the machine’s Documentation CD.
Console Buttons and Keys
References to console buttons and keys appear in bold text throughout the
documentation. For example, the Start Cycle button appears as the Start Cycle button
and the Manual key appears as the Manual console key in text.
Refer to the Getting Started with WinMax manual for information about console buttons
and keys, in addition to other information about using softkeys and the pop-up text entry
window.
Icons
This manual may contain the following icons:
Caution/Warning
The operator may be injured and the machine severely damaged if the
described procedure is not followed.
Softkeys
Status Bar
Error/Status area
Prompts
WinMax Version
Current Machine
Type (Desktop)

x - Documentation Conventions 704-0212-209 VM Series Maintenance and Safety Manual
Important
Troubleshooting
Hints and Tricks
Where can we go from here?
Table of Contents
Ensures proper operation of the machine and control.
?Steps that can be taken to solve potential problems.
Useful suggestions that show creative uses of the WinMax features.
Lists several possible options the operator can take.
To assist with onscreen PDF viewing, this icon is located on the cover page.
Click the icon to access the Table of Contents (TOC).
You can also access many of the same TOC entries from the Adobe Reader
bookmarks located on the left side of the PDF page.